Toyota chooses a Genesal emergency genset for its factory in Guanajato (Mexico)

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Toyota has trusted in Genesal to deliver emergency power to its Mexican factory in Apaseo el Grande, Guanajato.

The client needed something very specific: a back-up genset for the auxiliary equipment of the switching substation which serves the factory, for which we designed and supplied a 220 kVA special set, capable of providing the necessary support to the factory in the event of a mains failure.

The factory is one of the biggest projects carried out in the Apaseo el Grande municipality and will cause a great economic impact in the area, generating employment for 1.100 people. Furthermore, the installation will complete the production that the Japanese multinational corporation carries out in Baja California, where it currently produces around 170.000 units a year, of which nine out of ten are exported to the United States.

Precision and maximum reliability

In its first stage, this factory will assemble an average of 100.000 units a year of one of their star models: the Tacoma truck. In its second phase, the factory is estimated to produce 200.000 vehicles, reaching 300.000 before the year 2025. According to the company’s estimations, the factory is set to be operational towards the end of this very year.

The design of special generator sets to provide emergency power to great factories has been one of Genesal Energy’s focuses from the very beginning. Likewise, all of our gensets are custom-made after listening to each unique client with the objective to comply with their specific needs. In this case, the unit manufactured for Toyota’s new factory in Mexico has, amongst others, the following features:

Main Features

  • Double-walled 1000L fuel tank for 12 hours autonomy at 100% load.
  • Start-up through external command.
  • Communication system with SCADA System through TCP/IP protocol.

Risks and Consequences of Using Generator Sets at a Low Load Operation

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Minimum load for generators

Generator sets are designed to operate close to their rated power, and maintaining them properly is essential to ensure optimal performance. Every generator has a recommended minimum load, typically around 50% of its rated capacity. Operating below the generator minimum load for extended periods can lead to serious issues and reduced lifespan.

Main symptoms of something malfunctioning

One should be concerned when:

  1. The engine gives off oil mixed with fuel through the exhaust manifold – including the exhaust outlet or the muffler.
  2. There is oil spillage, dripping of oil of a very dark colour, as if burnt.
  3. The exhaust gives off a white smoke, more smoke than usual is seen or there is soot coming out of the exhaust outlet.
  4. The valves and tubing are clogged by dirt (presence of cinder).

The effect of low load on generator performance

“We saw engines working continuously for 24 hours at a tenth of their load and exhaust manifolds with six centimetre holes reduced to one centimetre by the accumulated cinder and oil”, Genesal Energy Technical Director Guillermo Docampo explains.

The effect of low load on a generator includes serious internal damage over time, particularly due to incomplete fuel combustion and oil dilution. These issues directly impact engine health and efficiency.

Negative effects of low load:

  1. Large accumulation of soot (cinder) in the pistons, in the grooves of the piston rings, in the valves and the turbocharger. If, subsequently, the engine functions at full load the pistons may be blocked by faulty lubrication.
  2. Low temperatures will result in insufficient combustion of the fuel, which, in turn, will cause the lubricating oil to be diluted and lose its properties because part of the fuel has mixed with the oil.
  3. Grinding of the cylinder liner. Excessive wear.
  4. The non-consumed fuel and the lubricating oil will also penetrate the exhaust manifold and will possibly exit through its seals, being very obvious -almost scandalous- because of its burnt aspect and by the stains it causes ((see photo below)).

Non-consumed fuel exiting through its seals

Important: Do not run an engine generator set without a load for more than 15–20 minutes unless strictly necessary. Prolonged operation without load can lead to internal damage, high oil consumption, and a shortened lifespan of the equipment.

Why does low-load functioning in a repeated and continuous way cause an increase in oil consumption?

In reality, when an engine works at a low load, the ideal working temperature of the engine is not attained. This favours oil flow towards the upper part of the piston, because a correct adjustment within the piston-rings-cylinder assembly was not achieved. This is due to the lack of dilation resulting in an increased consumption of oil; the oil flows more easily between the valve guides and the stems due to a greater clearance because there was no sufficient warming.

How to prevent malfunctions? Is it possible to reduce the risks?

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We’ve Reinforced Our Presence in Asia with Gensets in Taiwan, the Ever-Expanding Asian Tiger

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At Genesal Energy we’ve opened up a new market in Taiwan through the supply of a 500 kVA generator set designed to supply power in mains failure situations.

Our arrival to the Taiwanese market marks a turning point in Genesal’s internationalization plan in South East Asia. Taiwan is a strategic market, due both to its economic importance as the 28th wealthiest country worldwide and the 6th wealthiest in Asia, and to its potential for companies in the energy industry.

With a GDP that grows at a dizzying rate year by year, the power distribution sector is in constant evolution and with an increasingly strong focus on sustainability. As such, the first project we’ve carried out in the country, a stationary genset of 450-500 kVA, complies with Tier III emission standards. We delivered a genset which was completely adapted to the client’s requirements, providing the adaptability and flexibility needed for a correct integration of all components, with the following features:

  • Stationary, open type genset of 450-500 kVA at 60Hz, 380/220V.
  • DSE 7320 MKII control panel for automatic start at mains failure, with an Ethernet communication module to monitor the genset’s status remotely from a linked-up computer.

12 gensets for the Administration

Furthermore, our entry into the Taiwanese energy market has been consolidated through the supply of 12 gensets of 200/220 kVA for the Taiwanese Administration. The units, all customised, are designed to enter into operation should a mains failure ever occur. The gensets are stationary and were personalized according to the client’s requirements to be adapted to the modifications that would be carried out at a later date in their facilities. All of them comply with Tier III emission standards.

Main features

  • Open type stationary units of 200/220 kVA at 60Hz, 220/127 V.
  • DSE 7320 MKII control panel for start-up upon mains failure.
  • Engine with EGR valve for exhaust gas recirculation.
  • Alternator anti-condensation heaters.